May 2024

Choosing the right Powerstroke engine can feel like navigating a maze of options, especially for diesel enthusiasts well-versed in the industry. This comprehensive guide unpacks the 6.0L, 6.4L, and 6.7L Powerstroke engines to determine which reigns supreme. From reliability to performance, we’ll explore each engine’s strengths and weaknesses to help you make an informed decision.

How Reliable is the 6.4 Powerstroke?

When the 6.4 Powerstroke engine debuted in 2008, it captured the eyes of 6.0L Powerstroke enthusiasts, promising an improved design for reliability and better performance. It was also the first Ford engine to address newly introduced emissions standards. Known for power and not longevity, the 6.4 powerstroke has a mixed reputation for reliability. While some have praised the engine’s durability and power, others have noted common areas where it left more to be desired. Remember that the 6.4 powerstroke was the first engine to feature an advanced emissions control system, including a diesel particulate filter (DPF) and exhaust gas recirculation (EGR) system. With any new tech introduction, the complex systems were often linked to reliability challenges due to clogging or failure. 

What sets the 6.4 powerstroke engine apart in its design is the design of strong components like the bed plate and some of the strongest OEM rods used in a light-duty diesel engine. Did you know this engine features a high-pressure fuel pump with 20% more flow than its rivals during its production years?

To get the most out of your 6.4 Powerstroke crate engine, don’t forget about regular maintenance to keep your engine reliable. With diligent maintenance and attention to known issues, the 6.4 Powerstroke engine can provide reliable performance and longevity, reaching well over 200,000 miles in many cases. To maximize your time on the road, the 6.4 Powerstroke offers a variety of aftermarket solutions and parts.

How Long Will a 6.4 Powerstroke Last?

The longevity of a 6.4 Powerstroke engine can vary depending on several factors, including maintenance, driving conditions, and usage. While pushing back your oil changes can be tempting, the more you ignore caring for your engine, the more likely it is to miss major issues that can cause engine failure. A 6.4 Powerstroke can average 200,000 – 300,000 miles (322,000 – 482,000 km) with maintenance.

If you are considering a remanufactured 6.4 Powerstroke engine, keep in mind that the reman process’s quality should be considered. Opt for a reputable company with experience in remanufacturing diesel engines. A thorough remanufacturing process, including disassembly, inspection, machining, and reassembly with high-quality parts, can result in an engine that performs like new and has a long lifespan. Our experts at DFC Diesel can help you pinpoint what you are looking for in your 6.4 Powerstroke and engine upgrades, like the Speed of Air Hyperformance Pistons, that can give you more power and durability for your vehicle. 

Common 6.4 Powerstroke Reviews

For diesel fans who appreciate the inner workings of engines, the 6.4 Powerstroke engine boasts a mix of innovation and refinement. Despite some drawbacks, it has hidden qualities that shine through for those in the know.

• Powerhouse Performance: The 6.4 Powerstroke engine is known for its impressive speed and power. It’s hailed as the fastest diesel engine of its time, delivering thrilling acceleration and strong performance.
• Precision Engineering: With advanced technology like high-pressure fuel injection and a variable geometry turbocharger, the 6.4 Powerstroke showcases precision engineering, elevating its performance to a new level.
• Heavy-Duty Hauling: This engine excels in heavy-duty tasks, with plenty of torque and towing capacity to easily tackle even the most demanding jobs.
• Emissions Control: While emissions systems have caused some issues, the 6.4 Powerstroke engine tackles them head-on, striving for cleaner air without compromising performance.
• Refined Comfort: Compared to older models, the 6.4 Powerstroke offers a smoother and quieter ride, making for a more comfortable driving experience.

Despite its challenges, the 6.4 Powerstroke engine has much to offer for diesel enthusiasts. Its impressive performance, precision engineering, and ability to handle heavy-duty tasks make it a favourite among those who appreciate what lies under the hood.

Powerstroke Engine Breakdown: 6.0L vs 6.4L vs 6.7L

6.0L Powerstroke

• Pros:
  • Known for its impressive power output and towing capabilities.
  • Relatively simple design compared to later models, making it easier to work on for DIY enthusiasts.
  • Offers solid fuel economy when properly maintained.
• Cons:
  • Notorious for reliability issues, including EGR cooler failures, head gasket problems, and oil cooler issues.
  • Requires aftermarket upgrades to address common weaknesses.
  • Limited availability of replacement parts due to discontinuation.

6.4L Powerstroke

• Pros:
  • Improved performance over the 6.0L, with increased horsepower and torque.
  • Features advanced emissions control systems, including a diesel particulate filter (DPF) and exhaust gas recirculation (EGR) system.
  • Offers a smoother and quieter ride compared to its predecessors.
• Cons:
  • Reliability concerns persist, with issues such as turbocharger failures, high-pressure fuel system problems, and emissions system complexities.
  • Limited aftermarket support compared to the 6.0L and 6.7L engines.
  • Requires meticulous maintenance to prevent major failures.

6.7L Powerstroke

• Pros:
  • Considered the most reliable and robust of the three engines, with fewer reported issues overall.
  • Offers impressive power and torque, making it ideal for heavy-duty towing and hauling.
  • Features advanced technology, including a high-pressure standard rail fuel injection system and a variable geometry turbocharger.
• Cons:
  • Higher initial cost compared to older models.
  • Some owners report minor issues with emissions control systems, such as DEF (diesel exhaust fluid) injector failures.
  • Limited aftermarket support for performance upgrades compared to the 6.0L.

What Makes DFC Diesel 6.4 Powerstroke Engines Different? 

At DFC Diesel, we take pride in offering more than just engines—we deliver reliability, performance, and peace of mind. Here’s what sets our engines apart from the rest:

Long Block Assembly with Precision Engineering: Our long block assembly includes a complete short block assembly, gaskets, and O-ringed cylinder heads. Each engine is meticulously crafted with precision engineering to ensure optimal performance and durability.

Factory-Standard Rockers and Pushrods: We go the extra mile to ensure factory-standard quality by presetting all rockers and pushrods to factory specs—this meticulous attention to detail guarantees smooth operation and longevity.

Comprehensive Gasket Kit for Hassle-Free Installation: Say goodbye to guesswork and extra trips to the parts store. Our engines come with a complete top-end gasket kit, providing everything you need for a seamless installation process.

Enhanced Durability with ARP Connecting Rod Bolts: We prioritize durability and longevity by including ARP connecting rod bolts in every engine. These high-quality bolts ensure maximum strength and reliability under all conditions.

Advanced Sealing Methods for Leak Prevention: We’ve addressed common leakage areas with improved gasket sealing methods, ensuring a tight seal and minimizing the risk of leaks over time.

Premium Components Standard in Every Engine: Our commitment to quality shines through in every engine we produce. Each engine comes equipped with new pistons, rings, bearings, gaskets, seals, valves, springs, hardened seats, stem seals, and cast guides as standard, guaranteeing top-notch performance from start to finish.

Industry-Leading Warranty for Peace of Mind: We stand behind our products with confidence. Every DFC Diesel engine comes with a generous 5-year/160,000 km (100,000 mi) warranty for parts and labour, providing peace of mind and protection against unforeseen issues.

Are you ready for an upgrade? With our commitment to quality, precision engineering, and industry-leading warranty, you can trust that your engine will deliver exceptional performance for years. Request a quote today and experience the DFC Diesel difference firsthand with our remanufactured 6.4 Powerstroke engines for sale.